System and method for coating dimensionally stable construction materials

ABSTRACT

The invention relates to a system for coating dimensionally stable construction materials ( 1 ), especially facade components, as protection against environmental influences. The aim of the invention is to provide a system and a method for coating dimensionally stable construction materials, by which means the construction materials can be protected against atmospheric exposure in a rapid, simple and durable manner. To this end, a base material ( 2 ) having a rubber-elastic behaviour and containing a reinforcing mat ( 3 ) is applied to the construction material ( 1 ), and an outer layer ( 4 ) comprising an acyl copolymer as a binding agent is applied to the base material ( 3 ).

The invention relates to a system and a method for coating dimensionallystable construction materials, in particular facade components, asprotection against environmental influences.

Different materials which can be used as weather protection withlong-lasting effect were employed for coating dimensionally stableconstruction materials, for example wooden boards or masonry. These are,for example, gypsum fiber boards, wood fiber boards, sand-bound, glassfiber-reinforced lightweight concrete panels or rendering with acement-based render material.

Disadvantages of the materials used to date and known from the prior artare the limited applicability to various substrate materials and thevery complicated application of the weather protection to theconstruction materials in some cases. In addition, aging phenomena, suchas cracks or color changes, occur in the case of some coatings andrequire expensive reconstruction or renovation.

It is an object of the present invention to provide a system and amethod for coating dimensionally stable construction materials, by meansof which the construction materials can be protected from the influencesof weathering in a rapid, simple and durable manner.

According to the invention, this object is achieved by applying a basematerial having rubber-elastic behavior to the construction material, areinforcing mat being embedded in the base material. In a secondoperation, an outer layer which comprises a polymer, in particular anacrylic polymer, or a copolymer, in particular acrylic copolymer, as abinder is applied to this base material so that the resilient basematerial compensates movements within the coated construction material,and the outer layer provides a covering which is resistant to weatheringand resistant to environmental influences.

The base material advantageously contains a rubber, an elastomer or arubber material so that the base material is coatable and self-adhesive.This permits easy application to the construction material to be coated.The base material preferably contains milled rubber parts, partlycomprising recycled material, in order to reduce the consumption ofprimary raw materials.

In addition to the binder comprising acrylic copolymer, the outer layeror the material used as the outer layer contains titanium dioxides,quartz or calcite as fillers, resulting in a prevailing white base huewhich can be changed by adding color or colored pigments as desired. Itis also possible to produce a surface having different roughnesses bymeans of the fillers.

The reinforcing mat is advantageously woven fabric or knitted fabric inorder to increase the stability of the applied base material on theconstruction material, the reinforcing mat advantageously consisting offiber materials, in particular glass fibers. Owing to the mesh-likestructure of the mat, the dimensional stability of the self-adhesivebase material is increased.

Before application of the outer layer, the base material isadvantageously smoothed so that the outer layer, optionally the coloredouter layer, can be applied as desired on a base surface which is asflat as possible. For the sake of simplicity, the outer layer is appliedby spreading or filling, it being possible for application to beeffected by means of a brush or putty knife. When profiled putty knivesare used, virtually any desired structures of the outer layer on thebase material can be produced.

An embodiment of the invention is explained in more detail below withreference to the attached FIGURE which shows a model structure of abuilding facade.

The FIGURE shows a part of a building facade in a foundation, aconstruction paper or a construction sheet 6 having been applied to asupport structure 5. A dimensionally stable, panel-like constructionmaterial 1 is mounted, for example screwed on, in front of thisconstruction sheet 6. The construction material 1 is advantageously awood-base material, such as a particle board, an OSB board or a fiberboard, which can be used for erecting a facade. A skirting board 7 formsthe lower and outer end of the facade. As an alternative to thewood-base materials mentioned, the panels may also consist of concreteor styropor, and the facade may optionally also consist of a masonrymaterial.

The construction material 1 in its end position is then cleaned toremove impurities, and cracks and uneven areas present are filled. Thisensures that a smooth surface is present.

After the pretreatment of the surface to be coated, a reinforcing mat 3is cut to the desired dimensions, passages or cut-outs in the surfacebeing cut out with an excess of about 15 cm remaining at the edges. Abase material 2 comprising a material having rubber-elastic behavior isthen applied to the surface of the construction material 1 and at thesame time the reinforcing mat 3 is embedded in the coat of the basematerial 2. The base material 2 can be applied by means of a brush or atrowel; after application of the base material 2 on the surface of theconstruction material 1, said base material adheres by itself togetherwith the reinforcing mat 3 and forms a first protective layer for theconstruction material 1. The surface of the base material 2 can besmoothed, for example, by means of a brick trowel.

As an outer final coat, an outer layer 4 is applied, preferably bybrushing, to the surface of the base material 2, the outer layer 4consisting of an acrylic polymer or acrylic copolymer as a binder.Fillers, such as titanium dioxide, quartz or calcite, are added to thisacrylic polymer or acrylic copolymer, and the mixture is diluted bymeans of water. In order to ensure uniform processibility, the dilutionmust be constant, in particular in order to ensure a uniform color onaddition of colored pigments. The colored pigments are added to theacrylic copolymer/acrylic polymer immediately before the outer layer 4is brushed on and are mixed as desired. By using different brushes forbrush-coating or putty knife-coating tools, different structures of theouter layer 4 can be achieved, depending on which tools are used.

The system and method according to the invention reduce the workinvolved and hence the costs for weather protection by a coating or anouter layer of construction materials, such as wooden boards, fiberboards, OSB boards or other facade elements. The system is suitable inparticular as weather protection of wood components, such as wallelements for wooden houses by the panel construction method. As analternative to the use on wood-base materials, said system can be usedfor coating and for protection against influences of weathering ongypsum plasterboards, concrete or masonry. Owing to the rubber-elasticproperties of the base material 2, it is possible to provide a flexiblecoating resistant to weathering, it being possible to color the outerlayer 4 as desired. The coating thus protects the material used againstweathering by means of a hard and at the same time resilient covering.

By means of the system, protection against weathering is possible in allclimatic regions from extreme humidity to aridness, from intense heat totemperatures well below freezing. The starting materials of the basematerial 2 and of the outer layer 4 may be recycled products, so thatthe entire coating system is very environmentally friendly.

Owing to the rubber-elastic properties of the base material, the coatingis insensitive to hairline cracks in the outer coat, which may be causedby settling of the building or material movements relative to oneanother. The penetration of moisture into cavities is prevented, as isdamage by weather or wear.

The outer layer 4 can be provided with various degrees of graininess byadding corresponding fillers, so that a large number of designpossibilities is available. Owing to the self-adhesive properties of thebase material 2 and the low aggressiveness to other materials, it ispossible to use the coating on virtually any substrate from concrete tostyropor.

The base material 2 is prepared according to the formulation shownbelow. Material Amount in kg Addition of #1 and 2 and mixing at lowspeed for 2 minutes

#1 H2O 180.0 #2 KTTP 5.0 Add #3 to #6 at low speed

#3 296D 48.0 #4 N5667 308.0 #5 TEXANOL 7.2 #6 PRO-GLYCOL 8.8 Slowly add#7 until fluidization occurs, ensuring that nothing comes into contactwith the sides of the mixing container, in order to preventagglomeration Duration of mixing 10 minutes

#7 BENTOLITE WH 10.5 Add #8 + #9. Mix for 20 minutes at high speed

#8 CR-628 90.0 #9 MICRONA-7 268.0 Reduce the speed of the mixer tomiddle level. Add #10 to #13. In particular, ensure that #13 has theexact weight.

#10 COLLOID 640 1.0 #11 NUOSEPT-95 4.9 #12 NUO-404D 5.0 #13 AMMONIA 1.6Premix #14 into #15 in a clean tub and immediately add for mixing. Carryout the same with #16 + #17. Mix for 45 minutes. The mixture should besmooth and creamy.

#14 H2O 11.0 #15 BERMOCOLL 41I-FQ 2.8 #16 H2O 11.0 #17 BERMACOLL 41I-FQ2.8

Transfer the mixture to the blue mixer Add #18 and 19 - mix for 25minutes (do not mix for longer!) #18 −40 RUBBER FRAGMENTS 270.0 #19IMASCO SAND “0” 541.0 Fill tub up to 23 kg

1. A system for coating dimensionally stable construction materials (1),in particular facade components, as protection from environmentalinfluences, characterized by a base material (2) which is applied to theconstruction material (1) and has rubber-elastic behavior and in which areinforcing mat (3) is embedded, and an outer layer (4) which is appliedto the base material (2) and comprises a polymer, in particular anacrylic polymer, or a copolymer, in particular an acrylic copolymer, asa binder.
 2. The system as claimed in claim 1, characterized in that thebase material (2) contains a rubber, elastomer or rubber material. 3.The system as claimed in claim 1, characterized in that the basematerial (2) is brushable and self-adhesive.
 4. The system as claimed inclaim 1, characterized in that the base material (2) contains milledrubber parts, in particular recycled material.
 5. The system as claimedin claim 1, characterized in that the outer layer (4) contains titaniumdioxides and/or quartz and/or calcite as a filler.
 6. The system asclaimed in claim 1, characterized in that the outer layer (4) containscolored pigments.
 7. The system as claimed in claim 1, characterized inthat the reinforcing mater (3) is woven fabric or knitted fabric.
 8. Thesystem as claimed in claim 1, characterized in that the reinforcingmater (3) consists of fiber materials, in particular glass fibers.
 9. Amethod for coating a dimensionally stable construction material with acoat as protection from environmental influences, characterized in thata rubber-elastic base material (2) is applied to the constructionmaterial by brushing on and a reinforcing mat (3) is embedded in thebase material (2) and an outer layer (4) comprising a polymer, inparticular acrylic polymer, or a copolymer, in particular acryliccopolymer, as a binder, is then applied to the base material (2). 10.The method as claimed in claim 9, characterized in that the basematerial (2) is smoothed before the application of the outer layer (4).11. The method as claimed in claim 9 characterized in that the outerlayer (4) is applied by spreading or filling.